Partial calcification of free fatty acid mixtures, livestock feed compositions including them, and methods of making same

ABSTRACT

The present invention includes a nutritional supplement composition that may be used for livestock and the like, as well as to a livestock feed mixture containing same. Also included are methods of preparing the nutritional supplement composition, the livestock feed mixture, as well as methods of providing nutrition to livestock and the like. The livestock feed composition comprises: (a) a solid particulate livestock feed material and (b) a solidified particulate mixture of (i) free fatty acid and (ii) a calcium salt of a fatty acid, the calcium salt of a fatty acid being present in a molar ratio amount in the range of from about 25% to about 55% of the amount of the free fatty acid. The prefaced mixture is a solid having an onset melt point of between about 140 and 170 degrees Fahrenheit, and a hardness of from about 5 to about 15 Shore A units at 170 degrees Fahrenheit.

RELATED APPLICATION DATA

This application is a continuation application of U.S. patentapplication Ser. No. 14/814,936 filed Jul. 31, 2015, which is adivisional patent application of U.S. patent application Ser. No.12/755,800 filed on Apr. 7, 2010, (now U.S. Pat. No. 9,126,921), whichclaims the priority benefit of U.S. Provisional Application Ser. No.61/280,346, filed Nov. 2, 2009, each of which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

The present invention relates to nutritional supplement compositionsthat may be used for livestock and the like, as well as to a livestockfeed mixture containing them, and to their production and use.

Methods for producing calcium soaps have been known for many years inthe state of the art. Soaps are generally made from natural animal orplant fats containing triglycerides that comprise fatty acids, usuallylong-chain fatty acids, attached to the glycerol skeleton, which formsalts by means of a process of saponification in the presence of bases.

The fatty acids that most commonly form part of these triglycerides arelong-chain fatty acids such as oleic, stearic, palmitic, myristic,lauric, linoleic and linolenic acids. Fatty acids with much shorterchains also appear, such as butyric, capric, caprylic and caproic acids.

Strong inorganic alkaline metal bases, such as sodium hydroxide orpotassium hydroxide, are chosen as suitable bases for the saponificationreaction. In general, alkaline soaps are produced and their use islimited to cosmetics.

In the production of calcium soaps, calcium oxide (CaO) is added to thefats instead of adding alkaline metal hydroxide, which conditions theother parameters of the saponification reaction.

U.S. Pat. No. 4,642,317 discloses a process that makes it possible toincrease the proportion of fat fed to ruminants, without having adeleterious effect on the rumen microorganisms, which consists ofsupplying the animals with fatty acids in the form of previouslyprepared calcium salts. One of the examples of how to produce the saltsfrom natural fats mentions the prior saponification of the fats withsodium or potassium hydroxide, the separation of the phase containingthe alkaline metal salts and the subsequent dissolution of the phase inaqueous medium and mixing it with calcium salts.

U.S. Pat. Nos. 4,826,694, 4,853,233 and 4,909,138 also disclosecompositions for feeding ruminants wherein the main component (60-80% ofthe composition) is calcium or magnesium salts of longer-chain fattyacids (mainly with 14 to 18 carbon atoms), although it is also mentionedthat the presence of triglycerides (5%-15%) in the end product isimportant for the composition to be useful as feed for ruminants. Thepatents also disclose an apparatus and a process for producing theintended compositions, the process comprising, in this case, mixing oneor more basic oxides (preferably CaO) in excess with the fatty acids andtriglycerides and with water and, optionally, with an additionalnutritional material as a source of proteins, thoroughly homogenizingthe mixture to bring about the exothermic reaction that forms thecorresponding fatty acid salts, then spreading the mixture over a flatsurface so that most of the water evaporates. It is mentioned that oneof the preferred embodiments of the process involves pre-heating thefatty acids, e.g. to 80 degrees C.-100 degrees C., before mixing themwith the source of basic oxide, which is preferably lime (CaO).

Modifications to this basic process have subsequently been disclosed.For example, U.S. Pat. No. 5,234,701 discloses the inclusion of anaqueous solution of sodium carbonate-bicarbonate, which is a residualeffluent by-product of a bicarbonate production process, as the aqueousmedium for the calcium salt-forming reaction. This addition of sodiumcarbonate-bicarbonate seems to increase the efficiency of the process,thanks to the formation of a reaction intermediate consisting of thefatty acid sodium salt, which facilitates the formation of thecorresponding calcium salt.

Other patents stress the importance of the reaction conditions toproduce products with suitable characteristics when using sources offatty acids wherein a high proportion thereof are present in the form oftriglycerides. Thus, for example, U.S. Pat. No. 5,382,678 discloses theimportance of mixing the source of fatty acids with the source ofalkaline earth metal prior to adding water so that the end product isnot a powdery solid, but takes the form of tackless free-flowinggranules. It also discloses the importance of maintaining thetemperature of the reaction medium at a suitable value (40 degreesC.-130 degrees C.; 110 degrees C. is used in the examples) and for asufficient time to hydrolyze most of the glycerides that are present,releasing fatty acids that produce the desired alkaline earth metalsalts.

U.S. Pat. No. 6,229,031 also highlights the importance of maintaining asuitable temperature for long enough to achieve the saponification offatty starting materials with more than 45% triglycerides, againmentioning the need to supply the reaction mixture with additional heatas well as that generated by the exothermic reaction itself. In thiscase, the suitable temperature intervals mentioned are higher (90 degreeC.-250 degrees C.), with higher temperatures being preferred the lowerthe percentage of CaO that is added, which must be between 10% and 30%of the final composition.

U.S. Pat. Nos. 6,576,667 and 6,774,252 mention that the finaltriglyceride content must not exceed 5% of the total composition toprevent undesired alterations during storage, suggesting that the bestway to achieve sufficient saponification when using fatty materials richin triglycerides with a high omega-3 fatty acid content is to use 2 to 3equivalents of CaO relative to the starting material and 2 to 5equivalents of water relative to the CaO.

U.S. Published Patent Application No. 20090220638 discloses a process ormixing the natural fats or oils with the calcium oxide, then addingwater to the mixture and applying heat in a high pressure reactor. Afterreacting the fats and/or oils with calcium oxide, the reaction mass isallowed to cool. The calcium soap thus produced contains glycerol fromthe saponification of the triglycerides. No further washing,concentration (e.g. under vacuum conditions), or similar steps arenecessary. The soap need only be formed using conventional techniques ofextrusion into blocks, palletization, compression, granulation, etc.This reference discloses calcium soaps with a high fatty acid content(82-86%) are directly obtained after the saponification process, and istypical of attempts to carry out saponification more effectively, and tohandle purification of the saponification reaction mixture (i.e., byusing significant excess calcium oxide to drive the reaction to 100%glycerol, etc.).

Other patents relating to calcium soaps in animal feed compositionsinclude U.S. Pat. Nos. 7,318,943; 6,229,031; 5,783,714; 4,221,818;4,198,234; 4,062,988 and 4,016,296.

The foregoing references are hereby incorporated herein by reference.

Accordingly, the prior art has attempted to improve saponificationprocesses applied to fats to maximize the amount of fatty acid saltsobtained.

Typical of products currently on the market are 100% calcium soaps, suchas Megalac, commercially available from Volac Limited of Royston,England. These products are 100% salts usually of palm oil or soybeanoil fatty acids. Such products are generally made by saponification oftriglyceride fats, usually palm oil or soybean oil, with technology thatis well known. The 100% calcium soaps have a very high melt point (andactually decompose before melting) and thus cannot be prilledeffectively.

Beyond the problems of creating calcium salts of fatty acids ofsufficient nutritive value and digestibility (i.e., relatively highsalt/free acid ratio, especially for ruminants), another set ofconcomitant problems are associated with the transportation and use ofnutritional supplements of this sort relate to their transport, storage,handling and dispensing and use in processing. One of the problemsassociated with free fatty acid mixtures (100% non-salted) is that theytend to have relatively low onset melting points such that they may meltwhen exposed to elevated ambient temperature, such as when stored insilos, packaged in bags, subjected to the heat associated withprocessing or milling the material with base particulate feeds, orotherwise transporting the material in warmer weather or warm climates.

The relatively low onset melting points also adversely affect handlingand dispensing, as it more preferable to handle and dispense materials,both as a consumer and in industrial processing, that flow as arelatively dry, non-tacky particulate.

Another related problem is that the 100% free fatty acid products aresubject to caking and agglomeration upon being subjected to pressure,whether as a result of storage in silos, packing and transport in bags,etc.

Likewise, where it is desired to blend or mill such nutritionalsupplements so as to produce particulate livestock feed blends, currentfree fatty acid products are subject to melting or liquefaction duringprocessing, making them unsuitable for this type of industrialprocessing of this type. In this regard, while 100% salt products dohave acceptable bulk handling properties and can be pelleted, theycannot be prilled. The 100% calcium salted fatty acid products typicallyare all made from palm oil or soybean oil and with the higherunsaturated fatty acid level, these products have a negative nutritionaleffect on the rumen relative to the more saturated free fatty acidmixtures like Energy Booster 100 (EB 100), commercially available fromMSG Animal Nutrition of Adell, Wis.

Accordingly, there remains a need for nutritional supplements comprisingfatty acid mixtures or calcium salts of fatty acids that feature therequired nutritive value and digestibility, yet are improved withrespect to properties that are important to the transportation, storage,handling and industrial processing applied in the particulate livestockfeed blends.

SUMMARY OF THE INVENTION

The present invention includes a nutritional supplement composition thatmay be used for livestock and the like, as well as to a livestock feedmixture containing same. Also included are methods of preparing thenutritional supplement composition, the livestock feed mixture, as wellas methods of providing nutrition to livestock and the like.

The present invention includes a method of partially salting(calcifying/neutralizing) free fatty acids such that they can be prilledor flaked, exhibit improved compaction in bulk storage, improved flowand handling properties (flow from bulk bins, through augers, etc.), andcan be processed through traditional feed pelleting mills to make apelleted feed.

Although not limited to the theory of the invention, it is believedthese improved properties are a result of increased onset melt point andhardness vs. temperature, as compared to mixture of free fatty acids.

The preparation of 100% salts of fatty acids is well known and thesematerials are typically prepared by well established processes ofsaponification of triglyceride fats and oils.

In contrast to prior art methods, it is preferred that the process ofthe present invention starts with free fatty acids rather thantriglycerides, and produces directly a partially salted (calcified,neutralized) calcium salt of the starting fatty acid mixture, that is,the preferred starting material consists essentially of a fatty acid orfatty acid mixture. By simply neutralizing a mixture or free fatty acidswith, for instance, calcium oxide (i.e., no triglycerides present, noexcess calcium oxide, and no glycerol produced (which then has to beseparated)), the product of the present invention avoids thesedisadvantages associated with products made from fats directly. Theprocess of the present invention may also start with fats with thepurification of the fatty acids prior to further partial salting.

The free fatty acid products (like EB 100) have problematic flowproblems, and thus cannot be handled or used in bulk, and cannot bepelleted.

The 100% salt products do have good bulk handling properties and can bepelleted but they cannot be prilled. The 100% calcium salted fatty acidproducts are all made from palm oil or soybean oil and with the higherunsaturated fatty acid level, these products have a negative nutritionaleffect on the rumen relative to the more saturated free fatty acidmixtures like EB 100.

As a result of the process of the present invention, one may produce apartial calcium salt of fatty acid mixtures, i.e., from fatty acidmixtures such as those exemplified by EB100 fatty acid mixtures, andthereby produce products that have the best properties of both stale ofthe art technologies, i.e., EB100 free fatty acids and Megalac 100%calcium salts of palm oil fatty acids.

The partially salted fatty acid mixture of the present invention may beprilled or flaked, in accordance with methods known and used in the art.

The preferred fatty acid made and used in the present invention is amixture of tallow-free fatty acids and the calcium salts of tallow fattyacids, although the invention may be produced or practiced using anyfatty acid mixture, although with other mixtures, one may have to usehigher percent calcium for lower melting/softer mixtures. It is alsopreferred that the free fatty acids used in accordance with the presentinvention include those having a degree of unsaturation such that theiodine number is less than 20, most preferably less than 10.

Calcium may be incorporated in any form adapted to form the salt(s) ofthe fatty acid(s), as is known in the art such as in the form of calciumoxide or calcium hydroxide, in an amount equivalent to about 25% toabout 55% on a molar basis; i.e., in the range of from about 25 to about55% of the total moles of the tallow fatty acid(s), such that they areconverted (neutralized) to their calcium salts.

The melt point and hardness are a function of the percent calcification(i.e., percent neutralization). It is preferred that the onset meltpoint is about 170 F, although commercially important improvedproperties for handling, flow and pelleting can be obtained at meltpoints below 170 (through a melt point of 120-130 F such as that ofcommercially available EB100 is too low), and that the temperature forhardness of 15 Shore A units is about 170 F. A Shore A hardness lessthan 15 at 170 F (e.g. Shore A of 5-10 at 170 F) or a Shore A hardnessof 15 at a lesser temp than 170 F (e.g. Shore A of 15 at say 150 F)likely will yield good commercially important improved properties,though it is known that the properties of free fatty acid mixtures likecommercially available EB100 or its competitors do not have sufficientShore A hardness at 100-120 F to demonstrate improved properties forhandling flow and pelleting.

In contrast with current products, some of the novel properties and usesof the fatty acid mixtures of the present invention include that it maybe stored, transported and used in bulk (without compaction ordisadvantageous liquefaction), while comparative products, such as EB100(and other similar mixtures of free fatty acids from tallow, palm orsoy) cannot.

As one measure of the compressibility of the fatty acid mixtures of thepresent invention, a 50-100 gram/weight at 50 degrees centigrade for 1hour (about 2 psi-4 psi) did not result in compaction sufficient torestrict the ability of the flaked or prilled product to be poured(which conditions brought about compaction of EB 100).

One aspect of the present invention is drawn to a feed supplement forincreasing the fat intake level of animals, including animal feed andthe fatty acid mixture of the present invention. The animal feedtypically may be a dry feed.

The fatty acid mixtures of the present invention may be used forpelleted feed applications while comparative products, such as EB 100and other similar mixtures of free fatty acids from tallow, palm or soy,cannot be pelleted.

The fatty acid mixtures of the present invention may stored, transportedand used in dairies in hot climates (e.g., Florida, Arizona and NewMexico) while comparative products, such as EB 100 (and other similarmixtures of free fatty acids from tallow, palm or soy) cannot be handledin these climates without adverse effects on their physical form.

The fatty acid mixtures of the present invention also featurecontrollable, increased onset melt point and controllable, increasedhardness at all temperatures relative to free fatty acid mixtures. Thepresent invention thus offers a method by which the onset melt point canbe controlled and varied.

While a 100% calcium salt of a free fatty acid mixture of oils like palmoil and soy (which are liquid at room temperature) not only produces asolid product but one that has good flow properties and can be pelleted,it is also well known that the unsaturated fatty acids present palm andsoy have a negative effect on the rumen which limits the dose that canbe fed to dairy cattle.

It is also well known that mixtures of tallow fatty acids (with thelower degree of saturation compared to palm oil and soy are solids atambient temperature), can be prilled, but do not have good flowproperties and cannot be pelleted. It is also well known that tallowfatty acids, owing to their few level of unsaturation, do not have anegative impact on the rumen exhibited in the palm oil and soy fattyacid blends.

As to the increased onset melt point, a partially salted calcium salt ofa fatty acid mixture is a complex mixture of lower melting fatty acidsand non-melting calcium salts. Accordingly, these partially calcifiedcalcium fatty acid mixtures would likely not exhibit an increase inonset melt point since the non-salted fatty acids would melt at theirnormal melt point and the calcium salts would just be suspended in thematrix of fatty acids. By virtue of the present invention, and while notlimited to the theory by which it operates or achieves beneficialresults, it has been discovered that, by mechanisms not fullyunderstood, the calcium salts of a fraction of the free fatty acidspresent seem to complex with the remaining free fatty acids to form amixture that has an increased onset melt point. This increase in meltpoint was discovered to be positive and non-linear with increasingpercent calcium.

With respect to the hardness versus temperature, by the same rationaleas for increased onset melt point, it was not anticipated that thepartial salted calcium fatty acids would exhibit such an improvedhardness relative to the free fatty acids. What was discovered was thatby increasing the degree of salting by increasing the percent of calciumsalts of the fatty acids present that, by mechanisms not fullyunderstood, the calcium salts of a fraction of the free fatty acidspresent, seem to complex with the remaining free fatty acids to form amixture which is harder (as measured by Shore A) at any giventemperature up to the melt point relative to free fatty acid mixtures.This increase as with onset melt point is also non-linear.

The product of the present invention compares favorably to prior artformulations, such as that represented fey Energy Booster 100 (EB100)commercially available from MSG Animal Nutrition of Adell, Wis. TheEB100 is a prilled product, but may be made and sold as a flakedproduct. Prilling is a spray chilling process wherein the liquid fattyacid mixture is sprayed at the top of a tall tower into a chilled airstream forming very small spheres. The EB100 is a mixture of tallow freefatty acids (from animal fat), and features an onset Melt Point≤130 Fand a temperature for Hardness of 15 Shore A units at 120 F. It may beused as an energy source for high producing dairy cows. The problemsassociated with this product include that it cannot be used in bulkapplications (super sacks, bins, silos, trucks, etc.) due to compressioninto blocks, chunks, bridging, etc. In addition, it cannot be used forpelleted feed applications as pellet mash is at 160-185 degrees F. andthen is heated higher through the dies, because EB100 melts at 130degrees F. and thus binds the augers, sticks to the mash tank, and formsa soft pellet. It cannot be used conveniently on dairies in hot climates(e.g., Florida, Arizona, and New Mexico) owing to its susceptibility tosurface melting and resultant compaction.

In general terms, the invention thus includes a method of producing apartially calcified free fatty acid mixture, a partially calcified freefatty acid mixture, a livestock feed mixture containing a partiallycalcified free fatty acid mixture, a method of producing a livestockfeed mixture containing a partially calcified free fatty acid mixture, amethod of providing nutrition to livestock by feeding a mixturecontaining a partially calcified free fatty acid mixture, and a methodof providing nutrition to livestock by feeding a mixture containing apartially calcified free fatty acid mixture.

The method of producing a partially calcified free fatty acid mixturecomprises the steps of: (a) preparing a mixture of: (i) an amount of afree fatty acid; and (ii) an amount of a calcium-containing materialcomprising a calcium-containing basic compound adapted to form a calciumsalt of the fatty acid, the calcium-containing material being present ina molar ratio amount in the range of from about 25% to about 55% of theamount of a free fatty acid; and (b) maintaining the mixture atsufficient temperature and for sufficient amount of time so as to form amixture of free fatty acid and calcified free fatty acid. It will beappreciated that the mixture of free fatty acid and calcified free fattyacid may be obtained either by mixing the already salted fatty acid withfree fatty acid in a melt to obtain the desired ratio, or by proceedingfrom and free fatty acid (or mixture thereof) and subjecting it to apartially sailing reaction to obtain the desired ratio.

The free fatty acid may be selected from the group consisting of tallowand non-tallow fatty acids, and mixtures thereof, and the non-tallowfatty acids may be selected from the group consisting of fatty acidsfrom palm oil, soy oil, fish oil, linseed oil and flax oil, and mixturesthereof.

It is preferred that the reaction mixture is maintained at a temperaturein the range of from about 240 degrees to about 260 degrees Fahrenheitduring step (b).

The mixture may be additionally subjected to a prilling process or aflaking process, depending upon the desired product logistics parameters(storage, transport, etc.) and application.

The partiality calcified free fatty acid mixture of the presentinvention generally includes a composition comprising, and preferablyconsisting essentially of a solid particulate mixture of free fatty acidand a calcium salt of a fatty acid, the calcium salt of a fatty acidbeing present in a molar ratio amount in the range of from about 25% toabout 55% of the amount of the free fatty acid.

It is preferred that the free fatty acid comprises tallow fatty acid,sand that the calcium salt of a fatty acid comprises a calcium salt of atallow fatty acid, although the free fatty acid may be selected from thegroup consisting of tallow and non-tallow fatty acids, and mixturesthereof. The non-tallow fatty acids may fee selected from the groupconsistent of fatty acids from palm oil, soy oil, fish oil, linseed oiland flax oil, and mixtures thereof.

It is preferred that the mixture is a solid having an onset melt pointof at least 170 degrees Fahrenheit, and that it have a hardness of atleast about 15 shore A units at 170 degrees Fahrenheit, although one mayadjust the properties slightly with a range of a hardness of lesserShore A than 15 at 170 F (e.g. Shore A of 5-10 at 170 F, more preferably10-15 at 170 F) or a Shore A hardness of 15 at a lesser temp than 170 F(e.g. Shore A of 15 at 140-170, such as Shore A of 15 at 150 F) whilemaintaining the desired beneficial properties. Most preferably, themixture is a solid having an onset melt point of at least 170 degreesFahrenheit, and a hardness of up to 15 Shore A units (typically fromabout 5 to about 15 units) at 170 degrees Fahrenheit.

The invention also includes a livestock feed mixture containing apartially calcified free fatty acid mixture, the livestock feedcomposition comprises, and preferably consists essentially of: (a) asolid particulate livestock feed material and (b) a solidifiedparticulate mixture of (i) free fatty acid and (ii) a calcium salt of afatty acid (as described herein), the calcium salt of a fatty acid beingpresent in a molar ratio amount in the range of from about 25% to about55% of the amount of the free fatty acid.

The invention also includes a method of producing a livestock feedcomposition containing partially calcified fatty acid mixture,comprising the steps of: (a) preparing a blend of: (i) a solidparticulate livestock feed material and (ii) a solid particulate mixtureof free fatty acid and a calcium salt of a fatty acid (as describedherein), the calcium salt of a fatty acid being present in a molar ratioamount in the range of from about 25% to about 55% of the amount of thefree fatty acid, so as to obtain a solid particulate livestock feedcomposition; and (b) rendering the blend into a solid particulatelivestock feed composition.

The partially calcified free fatty acid mixture may be produced by aprilling process or a flaking process.

The solid particulate livestock feed composition preferably is renderedinto pellets, although other physical forms may be used.

The present invention further includes a method of providing nutritionto livestock by feeding a mixture containing a partially calcified freefatty acid mixture, the method comprising administering to a livestockanimal a solid particulate livestock feed composition comprising: (a) asolid particulate livestock feed material; and (b) a solid particulatemixture of free fatty acid and a calcium salt of a fatty acid (asdescribed herein), the calcium salt of a fatty acid being present in amolar ratio amount in the range of from about 25% to about 55% of theamount of the free fatty acid.

The solid particulate livestock feed composition preferably is in pelletform, and typically will be administered in nutritionally effectiveamounts in accordance with livestock care and nutrition practices knownin the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph of temperature versus reaction time showing a typicalreaction profile as may arise in accordance with one embodiment of thepresent invention;

FIG. 2 is a graph of melt point versus percent calcification showing aprofile as may arise in accordance with one embodiment of the presentinvention;

FIG. 3 is a graph of Shore A hardness versus temperature for multiplepercentages of calcification, and showing a profile as may arise inaccordance with one embodiment of the present invention;

FIG. 4 is a graph of temperature for a specified Shore A hardness versuspercent calcification for multiple percentages of calcification, andshowing a profile as may arise in accordance with one embodiment of thepresent invention;

FIG. 5 is a graph of Shore A hardness versus temperature for multiplepercentages of calcification, and showing a profile as may arise inaccordance with one embodiment of the present invention;

FIG. 6 is a graph of Shore A hardness versus temperature for multiplepercentages of calcification, and showing a profile as may arise inaccordance with one embodiment of the present invention; and

FIG. 7 is a graph of temperature for a specified Shore A hardness of 15versus percent calcification, and showing a profile as may arise inaccordance with one embodiment of the present invention.

FIG. 8 is a picture of a compression testing experimental setup used toassess the physical characteristics of compositions of the presentinvention.

FIG. 9 is a picture of test results of particulate matter as a result ofcompression testing, showing the comparative physical characteristics ofcompositions of the present invention and those of the prior art.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In accordance with the foregoing summary of the invention, the followingpresents a detailed description of the preferred embodiments, which areconsidered to be the best mode thereof.

The preferred method and compositions described herein are not intendedto be exhaustive or to limit the invention to the precise formsdisclosed. They are chosen and described to explain the principles ofthe invention and the application of the method to practical uses sothat others skilled in the art may practice the invention.

Example 1 of the Manufacturing Process of the Present Invention

As a preferred but non-limiting example of the method by whichcompositions of the present invention may be made, the following stepsmay be followed:

1. Heat mixture of free fatty acid to 205-240 degrees F.

2. Add desired molar equivalents of calcium as calcium oxide or calciumhydroxide with good mixing. The exothermic reaction of calcium oxide orhydroxide with free fatty acids causes temperature to rise to about260-280 degrees F. (dependent on insulation and heat loss of reactorsystem).

3. Hold reaction mixture at 240-260 degrees F. until reaction iscomplete as measured by change in Acid Value (AV). The reaction may bemonitored by determining Acid Value (AV) of the material; for example:for a target of 40% calcification the AV at completion would be about60% of the starting AV (i.e., AV final=0.6*AV starting).

4. When reaction is complete as determined in 3 above, material iseither prilled in a prilling (spray chilling) tower or flaked on arotary drum flaker by use of methods and apparatus well known in thefield.

Normally, the maximum percentage or fat attainable for the 100% calciumsoaps or the prior art is about 80-82% due to the 100% calcium levelwhile the maximum percentage of fat attainable is over 90 percent fatfor products made in accordance with the present invention.

While the 100% calcium soap products do not melt, the melt point andhardness can be controlled for the partially calcified products made inaccordance with the present invention.

The calcium soaps have historically been made from palm oil and soybeanoil. Both these oils and free fatty acid mixtures from these oils areliquids at room temperature and so to sell these products as a solidinto the dairy industry the companies using these starling materials hadto make the calcium soaps.

Example 2 of the Manufacturing Process of the Present Invention

A repeatable, controlled process was developed for partial calcificationof free fatty acids which included heating melted free fatty acids to205 F, slowly adding the calculated amount of calcium oxide and allowingthe reaction to proceed for approximately 2 hours after all calciumoxide was added. The temperature typically rises to 230-240 F shortlyafter the final addition of calcium oxide and remains in the range of220-230 F throughout the 2 hour reaction.

As an alternative to a timed reaction, the Initial Acid Value (AV) canbe obtained by known titration methods and the AV monitored throughoutthe reaction until AV value levels out (e.g. initial AV=185; for 40%calcification final AV=111).

A typical temperature-time profile is plotted in FIG. 1.

Melt Point and Hardness Properties of the Compositions

Melt point and hardness vs. temperature properties were determined fortwo different mixtures of fatty acids.

First Mixture=Initial AV of 185.

Second Mixture=Initial AV of 192.

Two Melt Points were determined.

Onset Melt Point=temperature at which first signs of melting areobserved.

Clear Melt Point=temperature at which no solid remains.

The Hardness was determined at various temperatures with a Rex VestPocket 1500 Durometer with a Shore A hardness scale.

Results are shown in FIGS. 2-7, the composition(s) made in accordancewith the present invention are designated as “EBH.”

Product Compression Properties

The product made from a fatty acid mixture with initial AV=185 wascalcified to 35% Ca and subjected to a simple compression test alongwith prilled 0% starting material and a 100% Ca-Salt commercial product(i.e., Megalac).

The set-up used to do this test is shown in FIG. 8.

Pulled materials were placed into a beaker with weights compressing theprills to create either 2 psi or 4 psi to simulate the compressiveforces of bulk storage.

The weighted beaker of prills was placed in a 50 degrees C. oven for 30min and then cooled to room temperature and tested for pourability andappearance.

Pictures were taken and are shown in FIG. 9.

From the data, a conclusion is that prilled 0% Ca starting materialmelted-compressed such that it was not pourable, while the 35% Caprilled material showed no significant signs of compression and pouredout of the beaker very well.

Product in accordance with the present invention may be suitable forbulk storage, such as in silos or otherwise, it may also be bagged forstorage and can even be transported or stored in relatively warmerclimates. By contrast prior art formulations, such as the EB100 productand other mixtures of free fatty acids from tallow, palm or soy cannot.

The product of the present invention also features a controllable,increased onset melt point, as well as a controllable, increasedhardness at all temperatures relative to free fatty acid mixtures of theprior art.

The product can be used as a feed supplement and may be formulated intofat supplementing animal feeds for livestock and the like. Examples mayinclude dairy cow rations. The animal feeds may be rendered intoparticulate or palletized form in accordance with and through the use ofequipment and methods known and used in the art. By contrast, thepelleted feed applications compare favorably to the EB100 product andother mixtures of free fatty acids from tallow, palm or soy, whichcannot be effectively pelleted.

While specific configurations and arrangements are discussed, it shouldbe understood that this is done for illustrative purposes only. A personskilled in the relevant art will recognize that other process andcomposition variations can be used without departing from the spirit andscope of the invention. It will be apparent to a person skilled in therelevant art that this invention can also be employed in a variety ofother applications.

What is claimed is:
 1. A composition comprising: a solidifiedparticulate mixture of free fatty acid; and a calcium salt of a fattyacid; wherein the composition has an onset melt point of from 140° F. to170° F.
 2. The composition of claim 1 wherein the free fatty acidcomprises tallow, non-tallow fatty acids, or a mixture thereof.
 3. Thecomposition of claim 1 wherein the free fatty acid comprises anon-tallow fatty acid comprising a fatty acid from palm oil, soy oil,fish oil, linseed oil, or flax oil.
 4. The composition of claim 3wherein the free fatty acid comprises myristic acid, palmitic acid,stearic acid, oleic acid, linoleic acid, or arachidic acid.
 5. Thecomposition of claim 1 wherein the composition has a hardness of atleast about 15 shore A units at 140° F.
 6. The composition of claim 1wherein the mixture of free fatty acid has an iodine number of less than20.
 7. The composition of claim 1 wherein the composition is pourableafter being compressed at 3 psi for one hour at 50° C.
 8. Thecomposition of claim 1 wherein the composition can be prilled or flaked.9. A livestock feed composition comprising: a solid particulatelivestock feed material; and a solid particulate mixture having an onsetmelt point of from 140° F. to 170° F. and comprising: a solidifiedparticulate mixture of free fatty acid; and a calcium salt of a fattyacid.